Carton and carton blank

ABSTRACT

Aspects of the disclosure relate to a package, a carton (90) for packaging one or more articles and a blank (10) for forming the carton (90). A plurality of panels (12, 14, 16, 18) define an interior of the carton (90) and include a first primary panel (16); a second primary panel (14) hinged to the first primary panel (16). A first end panel (16A/26A) is hinged to the first primary panel (16). A second end panel (24A) is hinged to the second primary panel (14). A gusset panel (34A) extends between and is hinged to the first end panel (16A/26A) and the second end panel (24A). An opening A3 defines a gusset edge (50A) provided by the gusset panel (34A) and a closure edge (50B) provided by the first end panel (16A/26A). A cut (52) extends from the opening (A3) into the first end panel (16A/26A).

TECHNICAL FIELD

The present invention relates to a carton for packaging one or more articles and a blank for forming the same, more specifically, but not exclusively to a carton having an improved folding structure.

BACKGROUND

In the field of packaging it is often required to provide consumers with a package comprising multiple primary product containers. Such multi-packs are desirable for shipping and distribution and for display of promotional information. For cost and environmental considerations, such cartons or carriers need to be formed from as little material as possible and cause as little wastage in the materials from which they are formed as possible. Another consideration is the strength of the packaging and its suitability for holding and transporting large weights of articles.

It is desirable to provide a carton the assembly of which can be automated and carried out in a packaging machine. It is desirable that the carton folds along the predefined fold lines and that the carton present clean fold lines for aesthetic purposes

The present invention seeks to overcome or at least mitigate the problems of the prior art.

SUMMARY

According to a first aspect of the present invention there is provided a blank for forming a carton. The blank comprises a plurality of panels for defining an interior of the carton. The plurality of panels comprises a first primary panel and a second primary panel hingedly connected to the first primary panel. A first end panel is hingedly connected to the first primary panel. A second end panel is hingedly connected to the second primary panel. A gusset panel extends between the first and second end panels and is hingedly connected to both the first and second end panels. The blank comprises an opening defined by a periphery which comprises a gusset edge provided by the gusset panel and a first closure edge provided by the first end panel. A cut extends from the opening into the first end panel.

Optionally, the cut extends from an intersection between the gusset edge and the first closure edge.

Optionally, the cut comprises an extension of the gusset edge.

Optionally, the gusset panel is hingedly connected to the first end panel along a weakened region including at least one first fold line, the second primary panel is connected to the first primary panel along at least one second fold line. The weakened region is greater in width than the at least one second fold line.

According to a second aspect of the present invention there is provided a carton for packaging one or more articles. The carton comprises a plurality of panels defining an interior chamber. The plurality of panels comprises a first primary panel and a second primary panel hingedly connected to the first primary panel. A first end panel is hingedly connected to the first primary panel. A second end panel is hingedly connected to the second primary panel. The carton comprises a gusset panel extending between the first and second end panels and hingedly connected to both the first and second end panels. An opening is defined by a periphery which comprises a gusset edge provided by the gusset panel and a first closure edge provided by the first end panel. A cut extends from the opening into the first end panel.

According to a third aspect of the present invention there is provided a blank for forming a carton. The blank comprises a plurality of panels for defining an interior of the carton. The plurality of panels comprises a first primary panel and a second primary panel hingedly connected to the first primary panel. A first end panel is hingedly connected to the first primary panel. A second end panel is hingedly connected to the second primary panel. A gusset panel is hingedly connected to the first end panel along a weakened region including at least one first fold line, the second primary panel is connected to the first primary panel along at least one second fold line. The weakened region is greater in width than the at least one second fold line.

Optionally, the at least one first fold line comprises a plurality of fold lines extending side by side with one another.

Optionally, an opening is defined by a periphery which comprises a gusset edge provided by the gusset panel and a first closure edge provided by the first end panel. The at least one first fold line extends from the opening toward an outer free edge of the gusset panel.

According to a fourth aspect of the present invention there is provided a carton for packaging one or more articles. The carton comprising a plurality of panels defining an interior chamber. The plurality of panels comprises a first primary panel and a second primary panel hingedly connected to the first primary panel. A first end panel is hingedly connected to the first primary panel. A second end panel is hingedly connected to the second primary panel. A gusset panel is hingedly connected to the first end panel along a weakened region including at least one first fold line, the second primary panel is connected to the first primary panel along at least one second fold line. The weakened region is greater in width than the at least one second fold line.

According to a fifth aspect of the present invention there is provided a carton for packaging one or more articles. The carton comprising a plurality of panels defining an interior of the carton. The plurality of panels comprises a first primary panel and a second primary panel hingedly connected to the first primary panel. A first end panel is hingedly connected to the first primary panel. A second end panel is hingedly connected to the second primary panel and is disposed at least in part in an overlapping arrangement with the first end panel. A gusset panel is disposed in face contacting arrangement with the first and second end panels. The gusset panel is hingedly connected to the first end panel by a region including at least one first fold line extending in a first direction. An opening is defined by a periphery which comprises a gusset edge provided by the gusset panel and a first closure edge provided by the first end panel. A separation element extends from the opening in a second direction into the first end panel. The region expands in the second direction along at least part of the separation element.

Optionally, the separation element comprises one of the features selected from the following group: a cut, a slot, a notch, and a recess.

According to a sixth aspect of the present invention there is provided a blank for forming a carton. The blank comprising a plurality of panels for defining an interior of the carton. The plurality of panels comprises a first primary panel and a second primary panel hingedly connected to the first primary panel. A first end panel is hingedly connected to the first primary panel. A second end panel is hingedly connected to the second primary panel arranged to be disposed at least in part in an overlapping arrangement with the first end panel. A gusset panel is foldable to be disposed in face contacting arrangement with the first and second end panels. The gusset panel is hingedly connected to the first end panel by a region including at least one first fold line extending in a first direction. An opening is defined by a periphery which comprise a gusset edge provided by the gusset panel and a first closure edge provided by the first end panel. A separation element extends from the opening in a second direction into the first end panel. The region expands in the second direction along at least part of the separation element.

Within the scope of this application it is envisaged or intended that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be considered or taken independently or in any combination thereof.

Features or elements described in connection with, or relation to, one embodiment are applicable to all embodiments unless there is an incompatibility of features. One or more features or elements from one embodiment may be incorporated into, or combined with, any of the other embodiments disclosed herein, said features or elements extracted from said one embodiment may be included in addition to, or in replacement of one or more features or elements of said other embodiment.

A feature, or combination of features, of an embodiment disclosed herein may be extracted in isolation from other features of that embodiment. Alternatively, a feature, or combination of features, of an embodiment may be omitted from that embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a plan view from above of a blank for forming a carton according to a first embodiment of the invention;

FIG. 1B is an enlarged view of a portion of the blank of FIG. 1 ;

FIG. 2 is a perspective view of a carton formed from the blank of FIG. 1 ; and

FIG. 3 is a perspective view of a portion of the carton of FIG. 2 during a stage of assembly.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Detailed descriptions of specific embodiments of the package, blanks and cartons are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented, and do not represent an exhaustive list of all of the ways the invention may be embodied. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. Indeed, it will be understood that the packages, blanks and cartons described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

Referring to FIGS. 1 and 1B, there is shown a plan view of a blank 10 capable of forming a carton or carrier 90 as shown in FIGS. 2 and 3 , which carton 90 can accept an input of primary products such as, but not limited to, bottles or cans, hereinafter referred to as “articles”.

In the embodiments detailed herein, the terms “carton” and “carrier” refer, for the non-limiting purpose of illustrating the various features of the invention, to a container for engaging, carrying, and/or dispensing articles, such as product containers. It is contemplated that the teachings of the invention can be applied to various product containers, which may or may not be tapered and/or cylindrical. Exemplary containers include bottles (for example metallic, glass or plastics bottles), cans (for example aluminium cans), tins, pouches, packets and the like.

The blank 10 is formed from a sheet of suitable substrate. It is to be understood that, as used herein, the term “suitable substrate” includes all manner of foldable sheet material such as paperboard, corrugated board, cardboard, plastic, combinations thereof, and the like. It should be recognized that one or other numbers of blanks may be employed, where suitable, for example, to provide the carrier structure described in more detail below.

In the embodiment illustrated in FIG. 1 , the blank 10 is configured to form a carton or carrier 90 for packaging an exemplary arrangement of exemplary articles. In the illustrated embodiment the arrangement is an m×n matrix or array, having three rows (m=3) and four columns (n=4); in the illustrated embodiment three rows of four articles are provided, and the articles are 405 ml cans; the cans may be formed from a suitable material such as, but not limited to, Aluminum. The blank 10 can be alternatively configured to form a carrier 90 for packaging other types, number and size of article and/or for packaging articles in a different arrangement or configuration.

The blank 10 comprises a plurality of primary panels 12, 14, 16, 18, 20 for forming a tubular structure or sleeve. A first primary or first side wall panel 12 is hinged to a second primary panel 14 (also referred to herein as a bottom panel 14) by a fold line (e.g., a core line or crease line) 13. The bottom panel 14 is hinged to a third primary panel 16 (also referred to herein as a second side wall panel 16) by a fold line (e.g., a score line or crease line) 15. The second side wall panel 16 is hinged to a fourth primary panel 18 (also referred to herein as a top panel 18) by a fold line (e.g., a score line or crease line) 17. The top panel 18 is hinged to a fifth primary panel 20 (also referred to herein as a securing panel 20) by a fold line (e.g., a score line or crease line) 19.

The first and fifth primary panels 12, 20 form a composite panel 12/20. The composite panel 12/20 forms a base wall 12/20 when a handle structure H is in use as a carrying handle by a user and this base wall 12/20 is optionally, disposed adjacent to the sides of the articles. In other words, the cylindrical axis of the articles is substantially parallel to the plane of the bottom wall 12/20 of the carton 90. In this orientation the third primary panel 16 forms a top wall disposed adjacent to the sides of the articles.

In FIG. 2 the carrier is shown in a loading orientation, the fourth primary panel 18 forms a top wall and the second primary panel 14 forms a bottom wall panel. The fourth primary panel 18 is disposed over the tops of the articles and the second primary panel 14 is disposed beneath the bases of the articles. The cylindrical axis of the articles is substantially perpendicular to the plane of the bottom second and fourth primary panels 14, 18.

As such, it will be understood that descriptive terms “top”, “base”, “bottom” and “side” do not necessarily limit the carton 90 to adopting a particular orientation but serve to distinguish those panels from one another.

The ends of the tubular structure are closed by end closure structures having a plurality of end closure panels 22A/12A, 24A, 26A/16A, 28A, 30A/20A, 22B/12B, 24B, 26B/16B, 28B, 30B/20B. A first end of the tubular structure is closed by a first group of end closure panels 22A/12A, 24A, 26A/16A, 28A, 30A/20A; the second end of the tubular structure is closed by a second group of end closure panels 22B/12B, 24B, 26B/16B, 28B, 30B/20B.

A first end closure panel 22A/12A is hinged to the first side wall panel 12 by a fold line 9A; a second end closure panel 24A is hinged to the bottom panel 14 by a fold line 23A; a third end closure panel 26A/16A is hinged to the second side wall panel 16 by a fold line 11A; a fourth end closure panel 28A is hinged to the top panel 18 by a fold line 27A and a fifth end closure panel 30A/20A is hinged to the securing panel 20 by a fold line 7A.

The first end closure panel 22A/12A and fifth end closure panel 30A/20A form a composite end closure panel 22A/12A/30A/20A. The first end closure panel 22A/12A and fifth end closure panel 30A/20A are secured together to form a first minor or side end closure flap 22A/12A/30A/20A.

The third end closure panel 26A/16A forms a minor or side end closure flap 26A/16A.

The second and fourth end closure panels 24A, 28A form major end flaps, the second end closure panel 24A forms a lower end closure flap 24A; the fourth end closure panel 28A forms an upper or top end closure flap 28A.

The first group of end closure panels 22A/12A, 24A, 26A/16A, 28A, 30A/20A is coupled one to the next by respective gusset or web panels 32A, 34A, 36A, 38A. A first web panel 32A is hingedly connected to the first end closure panel 22A/12A by a hinged connection or weakened region in the form of a fold line (e.g., a score line or crease line) F1. The first web panel 32A is hingedly connected to the second end closure panel 24A by a hinged connection in the form of a fold line (e.g., a line of perforations or cuts) F2. A second web panel 34A is hingedly connected to the second end closure panel 24A by a hinged connection in the form of a fold line (e.g., a line of perforations or cuts) F5. The second web panel 34A is hingedly connected to the third end closure panel 26A/16A by a hinged connection or weakened region in the form of a fold line (e.g., a score line or crease line) F6. A third web panel 36A is hingedly connected to the third end closure panel 26A/16A by a hinged connection or weakened region in the form of a fold line (e.g., a score line crease line) F9. The third web panel 36A is hingedly connected to the fourth end closure panel 28A by a hinged connection in the form of a fold line (e.g., a line of perforations or cuts) F10. A fourth web panel 38A is hingedly connected to the fourth end closure panel 28A by a hinged connection in the form of a fold line (e.g., a line of perforations or cuts) F13. The fourth web panel 38A is hingedly connected to the fifth end closure panel 30A/20A by a hinged connection or weakened region in the form of a fold line (e.g., a score line or crease line) F14.

A sixth end closure panel 22B/12B is hinged to the first side wall panel 12 by a fold line 9B; a seventh end closure panel 24B is hinged to the bottom panel 14 by a fold line 23B; an eighth end closure panel 26B/16B is hinged to the second side wall panel 16 by a fold line 11B; a ninth end closure panel 28B is hinged to the tope wall panel 18 by a fold line 27B, and a tenth end closure panel 30B/20B is hinged to the panel 20 by a fold line 7B.

The sixth end closure panel 22B/12B and tenth end closure panel 30B/20B form a composite end closure panel 22B/12B/30B/20B. The sixth end closure panel 22B/12B and tenth end closure panel 30B/20B are secured together to form a second minor or side end closure flap 22B/12B/30B/20B.

The eighth end closure panel 26B/16B forms a minor or side end closure flap 26B/16B.

The seventh and ninth enclosure panel 24B, 28B each form major end flaps. The seventh end closure panel 24B forms a second lower end closure flap 24B; the ninth end closure panel 28B forms a second upper or top end closure flap 28B.

The second group of end closure panels 22B/12B, 24B, 26B/16B, 28B, 30B/20B are coupled one to the next by a gusset or web panel 32B, 34B, 36B, 38B. A fifth web panel 32B is hingedly connected to the sixth end closure panel 22B/12B by a hinged connection or weakened region in the form of a fold line (e.g., a score line or crease line) F3. The fifth web panel 32B is hingedly connected to the seventh end closure panel 24B by a hinged connection in the form of a fold line (e.g., a line of perforations or cuts) F4. A sixth web panel 34B is hingedly connected to the seventh end closure panel 24B by a hinged connection in the form of a fold line (e.g., a line of perforations or cuts) F7. The sixth web panel 34B is hingedly connected to the eighth end closure panel 26B/16B by a hinged connection in the form of a fold line (e.g., a score line or crease line) F8. A seventh web panel 36B is hingedly connected to the eighth end closure panel 26B/16B by a hinged connection or weakened region in the form of a fold line (e.g., a score line or crease line) F11. The seventh web panel 36B is hingedly connected to the ninth end closure panel 28B by a hinged connection in the form of a fold line (e.g., a line of perforations or cuts) F12. An eighth web panel 38B is hingedly connected to the ninth end closure panel 28B by a hinged connection in the form of a fold line (e.g., a line of perforations or cuts) F15. The eighth web panel 38B is hingedly connected or weakened region to the tenth end closure panel 30B/20B by a hinged connection in the form of a fold line (e.g., a score line or crease line) F16.

The first side wall panel 12 is hingedly connected to proximal portions 12A, 12B of the end closure panels 22A/12A, 22B/12B at opposed ends of thereof. A first fold line 9A defines in part a first proximal portion 12A which forms a first corner panel 12A hingedly connected along a fold line 21A to a distal portion 22A of the first end closure panel 22A/12A. A second fold line 9B defines in part a second proximal portion 12B which forms a second corner panel 12B hingedly connected along a fold line 21B to a distal portion 22B of the sixth end closure panel 22B/12B.

The second side wall panel 16 is hingedly connected to proximal portions 16A, 16B of the end closure panels 26A/16A, 26B/16B at opposed ends of thereof. A third fold line 11A defines in part a third proximal portion 16A which forms a third corner panel 16A hingedly connected along a fold line 25A to a distal portion 26A of the third end closure panel 26A/16A. A fourth fold line 11B defines in part a fourth proximal portion 16B which forms a fourth corner panel 16B hingedly connected along a fold line 25B to a distal portion 26B of the eighth end closure panel 26B/16B.

The first, second, third, and fourth fold lines 9A, 9B, 11A, 11B may be non-linear, angled, curved or arcuate in shape.

The bottom panel 14 and top panel 18 each comprises filleted or chamfered corners, in the illustrated embodiment. In some other embodiments, the bottom panel 14 and top panel 18 each may comprise rounded corners, squared corners or a combination thereof.

In the illustrated embodiment, the fold lines 21A, 25A, 29A are collinear with each other. The fold lines 23A, 27A are collinear with each other. The fold lines 23A, 27A are offset with respect to the fold lines 21A, 25A, 29A. The fold lines 21B, 25B, 29B are collinear with each other. The fold lines 23B, 27B are collinear with each other. The fold lines 23B, 27B are offset with respect to the fold lines 21B, 25B, 29B. In other embodiments, the fold lines 21A, 25A, 29A each may be non-linear, angled, curved or arcuate in shape, although they may yet be arranged in generally alignment. In like manner, the fold lines 21B, 25B, 29B each may be non-linear, angled, curved or arcuate in shape, although they may yet be arranged in generally alignment.

The securing panel 20 is hingedly connected to proximal portions 20A, 20B of the end closure panels 30A/20A, 30B/20B at opposed ends of thereof. A fifth fold line 7A defines in part a fifth proximal portion 20A which forms a first inner corner securing panel 20A hingedly connected along a fold line 29A to a distal portion 30A of the fifth end closure panel 30A/20A. A sixth fold line 7B defines in part a sixth proximal portion 20B which forms a second inner corner panel 20B hingedly connected along a fold line 29B to a distal portion 30B of the tenth end closure panel 30B/20B.

The end closure panels 22A/12A, 22B/12B, 26A/16A, 26B/16B, 30A/20A, 30B/20B each include the proximal portions 12A, 12B, 16A, 16B, 20A, 20B and the distal portions 22A, 22B, 26A, 26B, 30A, 30B.

The proximal portions 12A, 12B, 16A, 16B, 20A, 20B may be considered to be parts of the end closure panels closing open ends of a tubular structure defined by the panels 12, 14, 16, 18, 20 in combination with the distal portions 22A, 26A, 30A, 22B, 26B, 30B and the end closure panels 24A, 28A, 24B, 28B. Alternatively, the proximal portions 12A, 12B, 16A, 16B, 20A, 20B may be considered to be the opposed end portions of the respective side wall panels 12, 16.

The blank 10 comprises a first cutaway A1 in the form of an aperture. The first cutaway A1 is struck in part from, or defined in part by, each of the bottom panel 14, first end closure panel 22A/12A, first web panel 32A and second end closure panel 24A.

The blank 10 comprises a second cutaway A2 in the form of an aperture. The second cutaway A2 is struck in part from, or defined in part by, each of the bottom panel 14, sixth end closure panel 22B/12B, fifth web panel 32B and seventh end closure panel 24B.

The blank 10 comprises a third cutaway A3 in the form of an aperture. The third cutaway A3 is struck in part from, or defined in part by, each of the bottom panel 14, second end closure panel 24A, second web panel 34A and third end closure panel 26A/16A.

The blank 10 comprises a fourth cutaway A4 in the form of an aperture. The fourth cutaway A4 is struck in part from, or defined in part by, each of the bottom panel 14, seventh end closure panel 24B, sixth web panel 34B and eighth end closure panel 26B/16B.

The blank 10 comprises a fifth cutaway A5 in the form of an aperture. The fifth cutaway A5 is struck in part from, or defined in part by, each of the top panel 18, third end closure panel 26A/16A, third web panel 36A and fourth end closure panel 28A.

The blank 10 comprises a sixth cutaway A6 in the form of an aperture. The sixth cutaway A6 is struck in part from, or defined in part by, each of the top panel 18, eighth end closure panel 26B/16B, seventh web panel 36B and ninth end closure panel 28B.

The blank 10 comprises a seventh cutaway A7 in the form of an aperture. The seventh cutaway A7 is struck in part from, or defined in part by, each of the top panel 18, fourth end closure panel 28A, fourth web panel 38A and fifth end closure panel 30A/20A.

The blank 10 comprises an eighth cutaway A8 in the form of an aperture. The eighth cutaway A8 is struck in part from, or defined in part by, each of the top panel 18, ninth end closure panel 28B, eighth web panel 38B and tenth end closure panel 30B/20B.

The first, second, third and fourth cutaways A1, A2, A3, A4 define chamfered, recessed, filleted or rounded corners of the bottom panel 14, such that the bottom panel 14 is substantially octagonal in shape.

The fifth, sixth, seventh and eighth cutaways A5, A6, A7, A8 define chamfered, recessed, filleted or rounded corners of the top panel 18, such that the top panel 18 is substantially octagonal in shape.

The first, second, third, fourth, fifth, sixth, seventh and eighth cutaways A1, A2, A3, A4, A5, A6, A7, A8 each form part of a relief structure, best shown with reference to FIG. 1B which shows an enlarged view of the third cutaway A3. The relief structures will be described in further detail by way of example with reference to the third cutaway A3 shown in FIG. 1B, the relief structures associated with the first, second, fourth, fifth, sixth, seventh and eighth cutaways A1, A2, A4, A5, A6, A7, A8 being similarly arranged. The third cutaway A3 provides an aperture or opening and is defined at least in part by a cut line 50. The cut line 50 defines a periphery of the aperture or opening. A separation element in the form of an extension cut line 52 extends from the cutaway A3 into the distal portion 26A of the third end closure panel 26A/16A. The cut line or periphery 50 comprises first portion 50A provided by an edge of the second web panel 34A and a second portion 50B provided by an edge of the third end closure panel 26A/16A. The first portion 50A of the periphery 50 defines a gusset edge 50A of the second gusset panel 34A. The second portion 50B of the periphery 50 defines a closure edge 50B of the third end closure panel 26A/16A. The first and second portions 50A, 50B define a vertex from which the extension cut line 52 extends. The extension cut line 52 extends from an intersection between the closure edge 50B and the gusset edge 50A. The extension cut line 52 may be oriented substantially perpendicularly to the second portion 50B of the cut line 50 although the extension cut line 52 may optionally oriented in a different direction at a different angle into the third end closure panel 26A/16A. The extension cut line 52 can be considered to be an extension of the first portion 50A of the periphery 50. The hinged connection or weakened region F6 hinging the second web panel 34A to the third end closure panel 26A/16A may comprises two or more fold lines arranged in parallel with each other. In the illustrated embodiment, the weakened region F6 comprises three parallel fold lines such as score or crease lines. In other embodiments, the weakened region F6 may be a single fold line in the form of a wide score line or crease line. The weakened region F6 may have width dimension W1 in the range 0.5 mm to 7 mm, optionally in the range 0.7 mm to 1.75 mm. The fold line F5 may have width dimension W3 in the range 0.25 mm to 3.5 mm, optionally in the range 0.7 mm to 1.75 mm. The weakened region F6 is disposed in general longitudinal alignment with the fold line 15 which interconnects the bottom panel 14 and the second side wall panel 16. The fold line 15 may be formed by a score line or crease line and may have width dimension W2 in the range 0.25 mm to 3.5 mm, optionally in the range 0.7 mm to 1.75 mm.

In the illustrated embodiment of FIGS. 1B and 3 , the separation element 52 is shown as a cut line. However, in other embodiments, the separation element may be a slot, a notch or a recess which extends from the respective cutaway into the respective end closure panel.

The width W1 of the weakened region F6 may be greater than the width W3 of the fold line F5 between the second gusset panel 34A and the second end closure panel 24A. The width W1 of the weakened region F6 may be greater than the width W2 of the fold line 15 between the bottom panel 14 and the second side wall panel 16. For example, but not limited to, the weakened region F6 may be at least twice the width of either the fold line F5 or the fold line 15, and may be up to five times the width of the fold line F5 or the folds line 15.

The weakened region F6 extends in a transverse direction x of the blank 10. In a setup condition the extension cut line 52 extends in a substantially vertical direction z of the carton 90, see FIG. 2 . The vertical direction is perpendicular to a longitudinal direction L_(A) of the carton 90 and to a transverse direction L_(T) of the carton 90.

The extension cut line 52 extends in a longitudinal direction y of the blank 10. In a setup condition the extension cut line 52 extends in the vertical direction z of the carton 90, see FIG. 2 .

Optionally, the first primary panel 12 comprises an opening A9 which may provide ventilation or expose a desired portion of an article disposed within the carton 90 to view.

The blank 10 may comprise a handle structure H. The handle structure H may be provided at least in part in the third primary panel 16. The handle structure H comprises a handle opening or slot defined in the third primary panel 16. The handle opening may be defined at least in part by a first handle tab 60A. The first handle tab 60A is struck from the third primary panel 16 and is hinged connected thereto by a hinged connection in the form of a fold line 61A. The handle opening may be defined at least in part by a second handle tab 60B. The second handle tab 60B is struck from the third primary panel 16 and is hinged connected thereto by a hinged connection in the form of a fold line 61B. The second handle tab 60B is hinged in opposition to the first handle tab 60A. The second handle tab 60B is separate from, or severable from the first handle tab 60A by a common cut line or severance line 59.

A line of separation 59 defines the center of the slot-type carrying handle H. The line of separation 59 is spaced a longitudinal distance from first and second ends of the third primary panel 16 (defined by fold lines 11A, 11B respectively). The line of separation 59 is located so as to be disposed centrally with respect to the first and second ends of the third primary panel 16. Optionally, in other embodiments, the slot-type carrying handle H may be disposed in an off-center position. The line of separation 59 is positioned such that when the blank 10 is formed into a carton 90 the line of separation 59 is located above a gap or void between two adjacent articles.

The line of separation 59 extends into each of the adjacent second and fourth primary panels 14, 18. In other embodiments, the slot-type carrying handle H may extend into only one of the adjacent second and fourth primary panels 14, 18. The line of separation 59 is optionally a perforate cut line comprising one or more or a series of connecting nick portions. Optionally nine connecting nick portions are provided in the third primary panel 16 along the line of separation 59; one nick portion is provided along the portion of the line of the separation 59 in the second primary panel 14; one nick portion is provided along the portion of the line of the line of separation 59 in the fourth primary panel 18.

Spaced either side of the line of separation 59 and within the third primary panel 16 a pair of fold lines 61A, 61B define each of the lifting edges of the slot-type carrying handle H. Between fold line 61A and line of separation 59 a cushioning flap 60A is formed, likewise, between fold line 61A and line of separation 59 a cushioning flap 60B is formed. The width of the cushioning flaps 60A, 60B may be controlled such that when folded beneath the plane of the third primary panel 16, the cushioning flaps 60A, 60B can fold within the gap between the third primary panel 16 and two adjacently located articles and at least partially underneath the third primary panel 16.

At each end of each cushioning flap 60A, 60B pairs of gussets are formed by crossed fold lines 71/73, 75/77. Optionally, the fold lines 71/73, 75/77 are disposed substantially at 90° relative to one another.

At each end of the slot-type carrying handle H a stress relief mechanism is provided which is tailored and configured to mitigate against stress build up or localized stress points in the carton 90 when the carton 90 is carried by the slot-type carrying handle H, in either direction (i.e. by using edges defined by fold lines 61A or 61B).

The stress relief mechanisms (also referred to as relief cuts) are identical and therefore only one will be described, it being understood that the details provided regarding one end of the slot-type carrying handle H are also true in respect of the other end of the slot-type carrying handle H.

An optional first curvilinear crease-cut line 63A, 67, 63B is provided in the second primary panel 14 and extends between the intersections of fold lines 61A and 61B with fold line 15.

The first curvilinear crease-cut line 63A, 67, 63B may be formed as a crease 63A, 63B along a first linear aspect and then optionally a full-depth cut line 67 on a second curved aspect. The first curvilinear crease-cut line 63A, 67, 63B and the line of separation 59 define a pair of foldable tabs each hinged to one of the cushioning flaps 60A, 60B.

An optional second curvilinear crease-cut line 65A, 69, 65B extends between the intersections of fold lines 61A and 61B with fold line 17. The second curvilinear crease-cut line 65A, 69, 65B may be formed as a crease 65A, 65B along a first linear aspect and then optionally a full-depth cut line 69 on a second curved aspect. The second curvilinear crease-cut line 65A, 69, 65B and the line of separation 59 define a pair of foldable tabs each hinged to one of the cushioning flaps 60A, 60B.

Optionally, the blank 10 comprises at least one dispenser D1, D2 for gaining access to the contents of the carton 90. The illustrated embodiment comprises two dispensers D1, D2.

A first dispenser D1 provides access to the carton 90 though an end wall provided by the first group of panels 22A, 24A, 26A, 28A, 30A.

A second dispenser D2 provides access to the carton 90 though the top panel 18 provided by the fourth primary panel 18.

The first dispenser D1 comprises a first severable line 80A/80B is provided in the second primary panel 14. The first severable line 80A/80B comprises a first portion 80B extending from the first cutaway A1 into the second primary panel 14 at an oblique angle to the fold lines 13, 23A. The first severable line 80A/80B comprises a second portion 80A extending from the fold line 23A into the second primary panel 14 at an oblique angle thereto. The first and second portion 80B, 80A extend to a tear initiation device I1. The first dispenser D1 comprises a second severable line 82 is provided in the second end closure panel 24A. The first dispenser D1 comprises a third severable line 84 is provided in the distal portion of the first end closure panel 22A/12A, extending from the fold line 21A to a free edge opposing the hinged edge defined by the fold line 21A; the third severable line 84 may be perpendicular to the fold line 21A. The first dispenser D1 comprises a fourth severable line 86 is provided in the fourth end closure panel 28A; the fourth severable line 86 defines a removable corner of the fourth end closure panel 28A. The fourth severable line 86 is substantially “L” shaped. The first, second, third and fourth severable lines 80A/80B, 82,84,86 define a tear out panel removing a portion of the end wall and a portion of a wall provided by the second primary panel 14.

The second dispenser D2 comprises a removable panel portion 18B defined in the fourth primary panel 18. The removable panel portion 18B is defined by a fifth severable line 40. The fifth severable line 40 is substantially “U” shaped and extends between the seventh cutaway A7 and the eighth cutaway A8. The second dispenser D2 comprises a tear initiation device 12. The tear initiation device 12 comprises a pair of tabs T1, T2 hingedly connected to the fourth primary panel 18 and defined in part by weakened lines of severance which are more readily severed than the fifth severable line 40.

Turning to the construction of the carton 90 as illustrated in FIG. 2 , the carton 90 can be formed by a series of sequential folding operations in a straight-line machine so that the carton is not required to be rotated or inverted to complete its construction. The folding process is not limited to that described below and may be altered according to particular manufacturing requirements.

The blank 10 is then folded about the fold line 17 such that the fourth primary panel 18 is brought into face to face relationship with a portion of the third primary panel 16 and the securing panel 20 is brought into face to face relationship with the second primary panel 14.

Glue G or other adhesive treatment is applied to the securing panel 20. In alternative embodiments glue or other adhesive treatment may be applied to the first primary panel 12.

Glue G or other adhesive treatment is applied to the distal portions 30A, 30B of the fifth and tenth end closure panels 30A/20A, 30B/20B. In alternative embodiments glue or other adhesive treatment may be applied to the distal portions 22A, 22B of the first and sixth end closure panels 22A/12A, 22B/12B.

The first primary panel 12 is folded about fold line 13 into face to face relationship with the second primary panel 14 and to face contacting relationship with securing panel 20. The first primary panel 12 is secured to the securing panel 20.

The distal portion 22A is brought into overlapping relationship with the distal portion 30A, the distal portion 22B is brought into overlapping relationship with the distal portion 30B.

The distal portion 22A is secured to the distal portion 30A. The distal portion 22B is secured to the distal portion panel 30B.

In this way, a flat collapsed tubular structure is formed. This flat collapsed tubular structure is suitable for shipping or distribution to a convertor plant.

The flat collapsed tubular structure can be erected into a carton by forming a tubular structure, engaging an adjacent pair of the plurality of primary panels 12, 14, 16, 18 and orientating an adjacent pair of the plurality of primary panels 12, 14, 16, 18 so as to be substantially perpendicular to each other. The tubular structure can then be loaded with articles by inserting the articles through one or both of the open ends of the tubular structure. The ends of the tubular structure are closed by folding the end closure panels 22A/12A, 24A, 26A/16A, 28A, 30A/20A, 22B/12B, 24B, 26B/16B, 28B, 30B/20B to be substantially perpendicular to the one of the plurality of primary panels 12, 14, 16, 18, 20 to which they are hinged.

The distal portion 22A is folded to be substantially perpendicular to the first primary wall panel 12. The first corner panel or proximal portion 12A is folded about the corner of the second and fourth primary panels 14, 18. The distal portion 26A is folded to be substantially perpendicular to the third primary panel 16. The third corner panel or proximal portion 16A is folded about the corner of the second and fourth primary panels 14, 18.

The second end closure panel 24A is folded to be substantially perpendicular to the second primary panel 14 such that it is in face contacting relationship with the distal portions 22A, 26A. The second end closure panel 24A may be secured to the distal portions 22A, 26A by adhesive or other suitable treatment.

The fourth end closure panel 28A is folded to be substantially perpendicular to the fourth primary panel 18 and is secured to the second end closure panel 24A, and may be secured to the distal portions 22A, 26A, by adhesive or other suitable treatment.

The second group of panels 22B, 24B, 26B, 28B, 30B is constructed in substantially the same manner to that of the first group of panels 22A, 24A, 26A, 28A, 30A previously described.

The assembled carton 90 is shown in FIG. 2 .

FIG. 3 shows a view of the carton 90 during construction, in a particular stage of construction of the end closure panels. The weakened region F6 is shown in overlying relationship with the fold line 23A. The increased width of the weakened region F6 compared to that of fold line 23A provides an increased degree of tolerance for aligning the fold lines F6, 23A with each other. The cut line 52 provides relief in the second end closure panel 24A. The cut line 52 allows a region of the distal portion 26A to be deformed or displaced. In this way, the distal portion 26A is distorted or deformed in preference to the second gusset panel 34A and/or the second end closure panel 24A. The cut line 52 facilitates formation of clean folds along fold line F5 and along weakened region F6 and may reduce the likelihood of deformation of the second gusset panel 34A. The second gusset panel 34A is disposed in close proximity or contacting relationship with the second end closure panel 24A.

The completed carton 90 comprises clean or uniform folds and the externally facing panels 18, 24A, 28A, 14, 24B, 28B, 12, 16 are free from distortion of deformation caused by incorrect or inaccurate folding or by misalignment of the panels.

The present disclosure provides a carton 90 and a blank 10 for forming the carton 90. The blank 10 comprises a plurality of panels 12, 14, 16, 18 for defining an interior of the carton 90 in a setup condition. The plurality of panels 12, 14, 16, 18 comprises a first primary panel 16; a second primary panel 14 hingedly connected to the first primary panel 16. A first end panel 16A/26A is hingedly connected to the first primary panel 16. A second end panel 24A is hingedly connected to the second primary panel 14. A gusset panel 34A extends between the first end panel 16A/26A and the second end panel 24A. the gusset panel 34A is hingedly connected to each of the first end panel 16A/26A and the second end panel 24A. An opening A3 is defined by a periphery 50 which comprises a gusset edge 50A provided by the gusset panel 34A and a first closure edge 50B provided by the first end panel 16A/26A. A cut 52 extends from the opening A3 into the first end panel 16A/26A.

The cut 52 may extend from an intersection of the gusset edge 50A and the first closure edge 50B. The cut 52 may define an extension of the gusset edge 50A.

The gusset panel 34A may be hingedly connected to the first end panel 16A/26A along at least one first fold line F6 and to the second end panel 24A along at least one third fold line F5. The at least one first fold line F6 may be greater in width than the at least one third fold line F5.

The present disclosure provides a carton blank 10 comprising a plurality of panels 12, 14, 16, 18 for defining an interior of a carton 90. The plurality of panels 12, 14, 16, 18 comprises a first primary panel 16, a second primary panel 14 hingedly connected to the first primary panel 16, and a first end panel 16A/26A hingedly connected to the first primary panel 16. A second end panel 24A is hingedly connected to the second primary panel 14. A gusset panel 34A is hingedly connected to the first end panel 16A/26A along a weakened region 6 including at least one first fold line, the second primary panel 14 is hingedly connected to the first primary panel 16 along at least one second fold line 15. The weakened region F6 is greater in width than the at least one second fold line 15.

The at least one first fold line may be longitudinally aligned with the at least one second fold line.

The weakened region F6 may comprise a plurality of fold lines extending side by side with one another.

The blank 10 may comprise an opening A3 is defined by a periphery 50 which comprises a gusset edge 50A provided by the gusset panel 34A and a first closure edge 50B provided by the first end panel 16A/26A. The at least one first fold line F6 may extend from the opening A3 toward an outer free edge of the gusset panel 34A.

The present disclosure also provides a carton 90 comprising a plurality of panels 12, 14, 16, 18 defining an interior of the carton 90. The plurality of panels 12, 14, 16, 18 comprises a first primary panel 16, a second primary panel 14 hingedly connected to the first primary panel 16. A first end panel 16A/26A is hingedly connected to the first primary panel 16. A second end panel 24A is hingedly connected to the second primary panel 14 and is disposed at least in part in an overlapping arrangement with the first end panel 16A/26A. A gusset panel 34A is disposed in face contacting arrangement with the first and second end closure panels 16A/26A, 24A. The gusset panel 34A is hingedly connected to the first end panel 16A/26A by a region F6 including at least one first fold line extending in a first direction L_(T). An opening A3 is defined by a periphery 50 which comprises a gusset edge 50A provided by the gusset panel 34A and a first closure edge 50B provided by the first end panel 16A/26A. A separation element 52—for example, but not limited to, a cut, a slot, a notch, a recess-extends from the opening A3 in a second direction L_(A) into the first end panel 16A/26A. The region F6 expands in the second direction L_(A) along at least part of the separation element 52.

It can be appreciated that various changes may be made within the scope of the present invention. For example, the size and shape of the panels and apertures may be adjusted to accommodate articles of differing size or shape.

It will be recognized that as used herein, directional references such as “top”, “bottom”, “base”, “front”, “back”, “end”, “side”, “inner”, “outer”, “upper” and “lower” do not necessarily limit the respective panels to such orientation, but may merely serve to distinguish these panels from one another.

As used herein, the terms “hinged connection” and “fold line” refer to all manner of lines that define hinge features of the blank, facilitate folding portions of the blank with respect to one another, or otherwise indicate optimal panel folding locations for the blank. A fold line is typically a score line, a crease line, an embossed line, or a debossed line. However, a fold line may be a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, an interrupted cut line, slits, scores, any combination thereof, and the like. Any reference to “hinged connection” or “fold line” should not be construed as necessarily referring to a single fold line only; indeed it is envisaged that a hinged connection can be formed from any one or more of the following: a short slit, a frangible line or a fold line without departing from the scope of the invention.

As used herein, the term “severance line” refers to all manner of lines that facilitate separating portions of the substrate from one another, or that indicate optimal separation locations. Severance lines may be frangible or otherwise weakened lines, tear lines, cut lines, or slits.

It should be understood that hinged connection, severance lines and fold lines can each include elements that are formed in the substrate of the blank including perforations, a line of perforations, a line of short slits, a line of half-cuts, a single half-cut, a cut line, an interrupted cut line, slits, scores, any combination thereof, and the like. The elements can be dimensioned and arranged to provide the desired functionality. For example, a line of perforations can be dimensioned or designed with degrees of weakness to define a fold line and/or a severance line. The line of perforations can be designed to facilitate folding and resist breaking, to facilitate folding and facilitate breaking with more effort, or to facilitate breaking with little effort. 

1. A blank for forming a carton, the blank comprising a plurality of panels for defining an interior of the carton, the plurality of panels comprising: a first primary panel; a second primary panel hingedly connected to the first primary panel; a first end panel hingedly connected to the first primary panel; a second end panel hingedly connected to the second primary panel; and a gusset panel extending between the first and second end panels and hingedly connected to each of the first and second end panels, wherein an opening is defined by a periphery which comprises a gusset edge provided by the gusset panel and a first closure edge provided by the first end panel, and wherein a cut extends from the opening into the first end panel.
 2. A blank according to claim 1 wherein the cut extends from an intersection between the gusset edge and the first closure edge.
 3. A blank according to claim 2 wherein the cut comprises an extension of the gusset edge.
 4. A blank according to claim 1 wherein the gusset panel is hingedly connected to the first end panel along a weakened region including at least one first fold line, wherein the second primary panel is hingedly connected to the first primary panel along at least one second fold line and wherein the weakened region is greater in width than the at least one second fold line.
 5. A carton for packaging one or more articles, the carton comprising a plurality of panels defining an interior chamber, the plurality of panels comprising: a first primary panel; a second primary panel hingedly connected to the first primary panel; a first end panel hingedly connected to the first primary panel; a second end panel hingedly connected to the second primary panel; and a gusset panel extending between the first and second end panels and hingedly connected to both the first and second end panels, wherein an opening is defined by a periphery which comprises a gusset edge provided by the gusset panel and a first closure edge provided by the first end panel, and wherein a cut extends from the opening into the first end panel.
 6. A blank for forming a carton, the blank comprising a plurality of panels for defining an interior of the carton, the plurality of panels comprising: a first primary panel; a second primary panel hingedly connected to the first primary panel; a first end panel hingedly connected to the first primary panel; a second end panel hingedly connected to the second primary panel; and a gusset panel hingedly connected to the first end panel along a weakened region including at least one first fold line, wherein the second primary panel is connected to the first primary panel along at least one second fold line, wherein the weakened region is greater in width than the at least one second fold line.
 7. A blank according to claim 6 wherein the at least one first fold line is longitudinally aligned with the at least one second fold line.
 8. A blank according to claim 6 wherein the weakened region comprises a plurality of fold lines extending side by side with one another.
 9. A blank according to claim 6 wherein an opening is defined by a periphery which comprises: a gusset edge provided by the gusset panel; and a first closure edge provided by the first end panel and wherein the at least one first fold line extends from the opening toward an outer free edge of the gusset panel.
 10. A carton for packaging one or more articles, the carton comprising a plurality of panels defining an interior chamber, the plurality of panels comprising: a first primary panel; a second primary panel hingedly connected to the first primary panel; a first end panel hingedly connected to the first primary panel; a second end panel hingedly connected to the second primary panel; and a gusset panel hingedly connected to the first end panel along a weakened region including at least one first fold line, wherein the second primary panel is connected to the first primary panel along at least one second fold line, wherein the weakened region is greater in width than the at least one second fold line.
 11. A carton for packaging one or more articles, the carton comprising a plurality of panels defining an interior of the carton, the plurality of panels comprising: a first primary panel; a second primary panel hingedly connected to the first primary panel; a first end panel hingedly connected to the first primary panel; a second end panel hingedly connected to the second primary panel and disposed at least in part in an overlapping arrangement with the first end panel; and a gusset panel disposed in face contacting arrangement with the first and second end panels, the gusset panel being hingedly connected to the first end panel by a weakened region including at least one first fold line extending in a first direction, wherein an opening is defined by a periphery which comprises: a gusset edge provided by the gusset panel; and a first closure edge provided by the first end panel, wherein a separation element extends from the opening in a second direction into the first end panel and wherein the weakened region expands in the second direction along at least part of the separation element.
 12. A carton according to claim 11 wherein the separation element comprises one of the features selected from the following group: a cut, a slot, a notch, and a recess.
 13. A blank for forming a carton, the blank comprising a plurality of panels for defining an interior of the carton, the plurality of panels comprising: a first primary panel; a second primary panel hingedly connected to the first primary panel; a first end panel hingedly connected to the first primary panel; a second end panel hingedly connected to the second primary panel arranged to be disposed at least in part in an overlapping arrangement with the first end panel; and a gusset panel foldable to be disposed in face contacting arrangement with the first and second end panels, the gusset panel being hingedly connected to the first end panel by a weakened region including at least one first fold line extending in a first direction, wherein an opening is defined by a periphery which comprises: a gusset edge provided by the gusset panel; and a first closure edge provided by the first end panel, wherein a separation element extends from the opening in a second direction into the first end panel and wherein the weakened region expands in the second direction along at least part of the separation element. 